Prefabricated building unit and structures made therefrom



Oct. 20, 1970 c, 5550 3,534,515

PREFABRICATED BUILDINGUNIT AND STRUCTURES MADE THEREFROM Filed Feb. 19, 1968 2 Sheets-Sheet 1 JNVENTOR. C424 5550 W MM c@ m M Get. 20, 1910 V c. F. BEED 3,534,515

PREFABRICATED BUILDING UNIT AND STRUCTURES MADE THEREFROM Filed Feb. 19, 1968 2 Sheets-Sheet a J2 f 63 f /32 INVENTOR. 64m A' 3550 United States Patent 3,534,5l Patented Oct. 20, 1970 3,534,515 PREFABRICATED BUILDING UNIT AND STRUCTURES MADE THEREFROM Carl F. Beed, 417 M St., Eureka, Calif. 95501 Filed Feb. 19, 1968, Ser. No. 706,521 Int. Cl. Etl4b 7/02; E04c 3/02; F16b 5/02 US. Cl. 52-92 1 Claim ABSTRACT OF THE DISCLOSURE A prefabricated building frame unit capable of being assembled with other units to constitute the framework for a cabin or other type building. The unit includes a pair of planar rectangular frames Whose perimeters are constructed of structural beams. Complementary horizontal beams of each frame are disposed immediately adjacent one another and joined together such that the frames mutually intersect at an obtuse angle. The obtuse angular joint connecting the frames adapts each unit to serve solely as a roof component or wall component or partially as a roof component and wall component in a structure. Each frame is made rigid by a series of diagonal struts arranged as truss support systems. Various structures employing standard, duplicate building frame units are disclosed.

BACKGROUND OF THE INVENTION (1) This invention lies in the field of standardized prefabricated building frame units and to structures employing them.

(2) The numerous beneficial attributes of prefabricated buildings have long been appreciated by the building industry and property owners. Prefabricated buildings can range in size from small vacation cabins to huge temporary or permanent dwellings. One meaning of prefabricated buildings refers to single precut structural pieces that are numbered or coded by the manufacturer so they can be nailed, screwed and glued together at the job site to form the shell of a building. Another meaning, with which the present invention is more closely related, refers to a package of structural pieces preassembled into sections such as wall, roof or floor components that require less labor and time to be joined together at the job site.

With the ever rising costs of labor and construction materials, factory-manufacturing buildings allow many to own primary and secondary homes who otherwise could not afford it. Significant cost savings are realized because less labor is required on the job site and payment for architectural and engineering skills is minimized through adoption of specific construction and design plans. Quick occupancy is possible because only minimal construction time is required. When numerous identical prefabricated sections are being fitted together at a factory in assemblyline fashion the workmanship is easily supervised. Adherence to particular standards of quality and finish relative to customary on-site house building can be greatly increased. Inferior sections or packages of prefabricated sections can easily be discarded at the factory. Waste is reduced by cost conscious factory managers. Sections can be easily constructed to satisfy local building codes so that, since much less on-site work is necessary, the risks of violating the building codes are substantially lessened.

There exists a wide assortment of prefabricated building components such as wall sections and roof sections capable of being interfitted or otherwise secured together to make the shell or basic framework for a building. Also truss-type roof rafters have been employed to replace hand cutting and nailing of the rafters during house construction. Other types of known sections are doors and windows hung in their frames at the factory and prebuilt stairways. Existing prefabricated sections are designed and constructed for installation in specifically designated building zones, e.g., certain sections are prepared for installation as wall portions while differently designed sections are prepared as roof portions. Prior art roof and wall sections are not interchangeable and cannot be used partially as roof portions and partially as wall portions even when such a dual function is highly desirable.

The present invention overcomes this single-use limitation as well as other disadvantages of prior art prefabricated building sections, by providing a building frame unit that is versatile with respect to various building portions and can be incorporated to form broadly differing types of building frameworks.

SUMMARY OF THE INVENTION The present invention comprehends a unique prefabricated building frame unit capable of being joined with identical or similar units to constitute the framework of various types of buildings such as vacation cabins, guest or week-end cottages, chalets, etc. Each unit is characterized by a pair of planar frames, each having at least one rectilinear beam. The perimeter of each frame includes a plurality of beams rigidly connected at their ends to one another and a series of diagonal struts arranged within the frames to constitute truss support systems. The rectilinear beams of each frame are set parallel and adjacent one another and are joined together so that the frames mutually intersect at an obtuse angle. The frames are fixed in this angular relationship by an obtuse angular joint characterized by the rectangular beams and fastening means securing them together. The obtuse angular joint may include a longitudinally extending shim or wedge positioned in a V-shaped groove defined by the oppositely facing sides of the adjacent rectangular beams. The beams and wedge can be secured together by nails, bolts, etc. Alternatively, a V-shaped angle plate may be inserted in the V-shaped groove, including a series of holes formed in both of its legs. These holes would register with bolt holes formed through the adjacent beams and be misaligned with each other so bolt heads would be adequately spaced along the beams. In accordance with another embodiment of the obtuse angular joint, gusset plates may be connected, at opposite ends of the adjacent beams, to the end beams of the frames.

The building frame unit is capable of being incorporated in a variety of architectural arrangements so that when used in a housing development project, for example, the houses would not necessarily possess look-alike appearances. By specially shaping the unit with an obtuse angular joint that holds the frames at the desired fixed obtuse angular relationship, the unit is made very versatile and can, for example, be installed solely as a roof component or wall component or can serve a dual purpose with one of its frames arranged as a roof component and the other frame as a wall component.

One of the many building embodiments that can be erected uses a pair of these building frame units arranged so that each constitutes one half of a gable roof and one wall, the obtuse angular joints serving as top plates. Another building embodiment uses four building frame units arranged so that two of them constitute a gambrel type roof while the other two constitute inclined walls. In a third embodiment four building frame units are arranged so that two constitute one-half of a flat roof portion and one-half of two inclined roof portions while two form the other halves of the inclined roof portions and short vertical side walls. In another embodiment one or more units in tandem are arranged to constitute an elongated gable roof cooperative with vertical studs. A fifth building embodiment incorporating four building 3 frame units has two units arranged with one of their frames in flush back-to-back relationship to constitute a partition. The other framesof the two units diverge from the adjacent obtuse angular joints and constitute roof portions. Additional units are included to complete the building framework with a double gable roof.

DESCRIPTION OF THE DRAWINGS The unique aspects and advantages of the present invention will be understood from the following detailed description in conjunction with the drawings in which:

FIG. 1 is a perspective view of the prefabricated building frame unit showing the two frames connected together and mutually intersecting at an obtuse angle.

FIG. 2 is a transverse sectional view taken along line 2-2 of FIG. 1, showing the obtuse angular joint to include a wedge.

FIG. 3 is a transverse sectional view similar to the view shown in FIG. 2, showing an alternate obtuse angular joint including an angle plate.

FIG. 4 shows another embodiment of the obtuse angular joint characterized by a gusset plate connected to the end beams of the frames forming the unit.

FIG. 5 is a perspective view of the framework of a building structure with a gable roof, incorporating two prefabricated building frame units also providing inclined walls.

FIG. 6 shows another building structure with a gambrel-type roof, incorporating four prefabricated building frame units.

FIG. 7 shows yet another building structure embodiment with a fiat roof, incorporating four prefabricated building units.

FIG. 8 shows another structural embodiment incorporating one, or a plurality in tandem, building frame units for a roof.

FIG. 9 shows still another structural embodiment incorporating four prefabricated building units, two frames of which are arranged to constitute a partition.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the drawings, FIG. 1 shows a basic prefabricated building frame unit 10 which by itself or coupled with additional units can be incorporated in a broad variety of structural arrangements to constitute the basic framework for buildings or the like. A few of the unlimited number of possible structures which can be erected using these building frame units as prime components will be explained in detail. Building frame unit 10 is constructed from a pair of substantially rigid frames 12 and 14 which are of rectangular shape. The perimeters of frames 12 and 14 are constituted respectively by structural beams 15, 16, 17 and 18 and structural beams 21, 22, 23 and 24, respectively, which may be standard 2" x 4" in cross-section. Although frames 12 and 14 are preferably of rectangular shape, they may be of any other quadrangular shape or may include more than four structural beams. At least structural beams and 21 are rectilinear so they can be arranged in parallel, abutting relationship and fixed securely together. While it is contemplated that for most building requirements, frames 12 and 14 will be of identical shape, one frame may be longer, wider, or differently shaped than the other.

Frames 12 and 14 are relatively located so their planes intersect at an obtuse angle. Beams 15 and 21 are fixed together to constitute a rigid obtuse angular joint 25 which maintains the frames in the desired relationship. The particular obtuse angle can be determined during the prefabrication stage to satisfy predetermined requirements. Alternative obtuse angular joint constructions will be described in conjunction with FIGS. 2, 3 and 4. To reinforce the rigidity of frame 12, a series of struts 27 extend diagonally between parallel beams 15 and 17.

In like manner, a series of struts 29 extend diagonally 75 4.- between parallel beams 21 and 23. Each arrangement of diagonal struts and its associated frame constitutes a truss framework (i.e., a system of structural members attached together at their ends to form triangles) to achieve outstanding deformation resistance to external forces. Rather than using truss frameworks, or in addition thereto, the frames can incorporate shear panels characterized by diaphragms constructed of plywood or the like. Rigid rectangular frames 12 and 14 are prefabricated and may be joined together by the manufacturer as a prefabricated building frame unit 10 or may be so' connected in the field. Although the various building frame unit components are preferably made of standard wood sections, they may be made from other materials such as extruded aluminum, plastics, etc., and may be of any desired cross-sectional shape.

FIG. 2 shows one type of obtuse angular joint 25 for rigidly joining the rectangular frames 12 and 14. Two shims or wedges 31 are inserted in the V-shaped groove defined by the oppositely facing outer faces 35 and 36 of rectilinear beams 15 and 21. The Wedges may be adhesively bonded to each other and to their respective abutting beam faces. Nails are driven through beams 15 and 21 and wedges 31 to fix the frames 12 and 14 in the desired obtuse angular relationship, or bolts or other connectors may be used.

FIG. 3 shows that, alternatively, the frames may be joined together to form an obtuse angular joint 25 by inserting an offset, longitudinally extending, metal angle connector 37 into the V-shaped groove defined by outer beam faces 35 and 36. Leg plates 38 and 39 of connector 37 are offset longitudinally and have drill holes therethrough which register with complementary drill holes formed in the beams 15 and 21. The holes through offset leg plates 38 and 39 are likewise offset so fastening nuts 41 and 43 will be longitudinally offset from one another. By providing this clearance between opposing sets of fastening nuts 41 and 43, the assembling and tightening operations are facilitated. The angle of the leg plates of connector 37, as well as the combined angle of wedges 31 shown in FIG. 2, is established so that the desired obtuse angle between the rigid frames will be obtained when the joint is tightened.

A different type of construction for making an obtuse angular joint 25, shown in FIG. 4, is characterized by attaching a pair of corner tie bars or gusset plates 45 to the end beams 16, 22 and 18, 24 at the ends of adjacent beams 15 and 21. Gusset plate 45 is shown secured by bolts 47 to the end beams 16 and 22 in FIG. 4. The particular shape of gusset plate 45 and the number of bolt holes are dictated, among other considerations, by the anticipated shear, buckling and other forces that might tend to deform the building unit. Adjacent beams 15 and 21 may, if desired, also be interconnected in accordance with the constructions described with respect to FIGS. 2 or 3.

By fixing the two frames at an obtuse angle many desirable building frameworks can be built up from standard prefabricated building frame units. The units can interchangeably be incorporated as roof components, wall components or can be used partly as a wall component and partly as a roof component. The advantages of the building frame units of this invention will be more fully understood when the following specific building framework embodiments are described. These embodiments merely serve to illustrate some of the many building framework arrangements which may be built up using the standard units.

One type of building that can be constructed from the described prefabricated building units is a dwelling 50- illustrated in FIG. 5 which may be a cabin, cottage, chalet or the like. A pair of building units 10 are tilted toward one another and propped in place for nailing, etc. They are arranged relative to one another so that one frame of each constitutes one inclined wall of dwelling 50 and the other frame of each one-half of a gabletype roof. In the basic framework of dwelling 50 beams 23 serve as bases secured by bolts 52 to a concrete foundation 53. Obtuse angular joints 25 are the top plates and the beams 17 are rigidly joined together by any suitable conventional connectors to form a ridge pole or board 54. In addition to rigidifying the dwelling framework, oppositely diagonal struts 27 support a roof covering 56 and oppositely diagonal struts 29 support side sheathing 58. Structural beams 16, 18 and 22, 24 constitute four inclined corner posts. A minimal number of additional components, which may or may not be included with the units as pieces of a prefabricated package, are required to complete the framework of dwelling 50. Thus, extending between the forward ends of beams 23 is a pair of frontal joists 61 connected to a pair of upright studs 63. Lower portions of studs 63 serve as jambs and coact with a lintel 64 to form a door frame. A window frame 65 is incorporated between a pair of diagonal struts 29. It can be seen that dwelling 50 can be quickly and easily erected by a carpenter, contractor or a homeowner from two basic prefabricated building frame units assembled together and joined to some minimal number of additional framework components.

Another building 60 formed in accordance with the present invention, shown in FIG. 6, has a gambrel-type or double sloped roof constituted by two building frame units 66 and 67, each of which forms one half of the roof. They are rigidly joined together to form a ridge board 62. The lower depending frames of units 66 and 67 are attached to units 68 and 69 respectively, that serve as additional roof and side walls. Supporting studs and joists 59 may be incorporated in the structure.

FIG. 7 shows another building 70 with a fiat top roof portion constituted by building units 71 and 72 arranged with one frame of each in edge abutting, coplanar relationship. Their other frames are aligned in edge abutting, coplanar relationship with frames of building units 73 and 74, respectively, to form opposite side, sloping roof portions. The lower frames of units 73 and 74 serve as low vertical walls and are supported upon a suitable foundation to rigidify the framework of building 70. A series of internal braces 76 are connected to the units.

FIG. 8 shows a simple structural embodiment characterized by a building 80, such as a cabana, having one (or more in tandem) unit 81 supplying the roof framework and being supported on side studs 82 and end studs 83. End bracing struts are shown at 84.

FIG. 9 shows a duplex or compartmentalized cabin 85 having two building units 86 and 87 arranged with one frame of each in flush, back-to-back relationship to constitute a partition 89 dividing the interior into two rooms 90 and 91. The other frames of units 86 and 87 diverge from their adjacent obtuse angular joints to form one half of the roofs for rooms 90 and 91, respectively. Two additional units 94 and 95 are rigidly connected to the units 86 and 87, respectively, to form ridge boards 96 and 97 for the double gable roofs above rooms 90 and 91, respectively. Unit 94 serves the dual purpose of being a roof section and wall section for room 90 while unit 95 serves as a roof section and wall section for room 91.

While certain embodiments have been chosen to best illustrate the unique aspects and advantages of this invention, it is to be understood that the scope of the invention is to be limited only by the following claim.

I claim:

1. A prefabricated building frame unit cooperating with other frame components to form the framework of a building, the unit comprising:

a first planar rectangular frame whose perimeter is defined by structural beams,

a second planar rectangular frame whose perimeter is defined by structural beams, one of which is located parallel to and immediately adjacent a beam of the first frame,

an angular joint for joining the adjacent beams together so that the frames mutually intersect in an obtuse angle,

a plurality of oppositely diagonal struts arranged within each frame between the top and bottom beams to constitute truss support systems to carry the loads along the frames to their ends,

said angular joint comprising:

a longitudinally extending angle plate connector positioned in a V-shaped groove defined by oppositely facing sides of the adjacent beams,

21 series of openings formed in each leg plate of the connector, the series of openings being in registering alignment with fastener holes formed in corresponding beams,

fasteners positioned through the holes and openings for securing the connector and beams together, and

the leg plates of the connector being longitudinally offset so that fastener portions extending into the V-shaped groove are off-set from one another.

References Cited UNITED STATES PATENTS 701,658 2/1905 Kassens 52-93 1,129,658 2/1915 Foy 287-2092 X 1,375,402 4/1921 McAvoy 52-90 1,981,166 11/1934 Duttweiler 52-90 X 2,095,434 10/1937 Calkins et a1. 52-90 X 2,263,214 11/1941 Larkin et a1. 52-90 2,272,910 2/ 1942 Gobberdiel 52-90 X 2,300,113 10/1942 Faber 52-93 2,350,904 6/1944 King 52-93 X 2,396,829 3/ 1946 Carpenter 52-94 X 2,796,642 6/ 1957 Woodworth 52-93 X 3,204,375 9/ 1965 Kotarski 52-94 3,193,973 7/1965 Lee et a1. 52-693 X FOREIGN PATENTS 414,401 1910 France. 43 4,281 1948 Italy.

U.S. C1. X.R. 

